Method of Manufacturing a Lightweight Wheel With High Strength Flexible Spokes

ABSTRACT

A method of manufacturing a lightweight wheel with high strength flexible spokes of the present invention, includes providing a rim and hub, and a plurality of lightweight, flexible and resilient spokes between the rim and hub made of fibrous material that causes the spokes to be both lighter in weight and stronger than comparable steel spokes. The wheel includes a nipple within the rim that receives the high strength spoke and allows for flexibility in adapting the spoke to wheels having differing shapes and sizes.

RELATED APPLICATION

This application is a continuation, and claims the benefit of priorityto U.S. Utility patent application Ser. No. 15/597,449 filed May 17,2017 and currently co-pending which in turn claims priority to U.S.Utility patent application Ser. No. 14/519,312 filed Oct. 21, 2014,issued as U.S. Pat. No. 9,682,596, which further claims the benefit ofpriority to, U.S. Utility patent application Ser. No. 13/492,573entitled “Wheel With High Strength Flexible Spokes,” filed Jun. 8, 2012and now U.S. Pat. No. 8,985,708, which is a continuation-in-part of, andclaims the benefit of priority to, U.S. Utility patent application Ser.No. 13/487,253 entitled “Wheel With Flexible Wide-Body Spokes,” filedJun. 4, 2012 and now U.S. Pat. No. 8,985,707.

FIELD OF INVENTION

The present invention is directed to vehicular wheels havinghigh-strength and light-weight spokes, particularly bicycle, motorcycle,and wheelchair wheels.

BACKGROUND OF INVENTION

The most common construction for bicycle wheels includes spokes made ofstainless steel or other metal. While stainless steel is strong, it isalso heavy. Therefore, the spokes must be made as thin as possible tomake them as light as possible. However, the thinner the spoke, the lessstrength it has. The thicker the spoke, the stronger it is. Therefore,in making spokes of steel, there is a tradeoff between making the spokesstrong and making them lightweight. Thus, there is a need for a wheelwith spokes that can be both lightweight and strong without having todeal with this tradeoff between the two. Another problem with steelspokes is that, if they are bent, they weaken and ultimately fail suchthat they must be replaced if bent.

One solution to this problem was presented in U.S. Pat. No. 5,110,190which issued to Harold Johnson on May 5, 1992, for an invention entitled“High Modulus Multifilament Spokes And Method” (hereinafter the “'190patent”). The '190 patent is fully incorporated herein by thisreference. The '190 patent discloses a high modulus multifilamentnon-rigid and rigid wheel spoke that includes a fiber mid-portionbetween a first and second end having attachment members affixedthereto. The '190 patent also discloses methods of supporting a hubwithin a wheel rim by means of a plurality of spokes or by means ofcontinuous lengths of spokes.

While the device presented in the '190 patent clearly made advancementsover the state of the art at that time, the device nevertheless has itsshortcomings. For instance, the small diameter of the filament spokesrequires that the spokes be maintained in a substantially axialarrangement with its connectors. This, unfortunately, makes themanufacturing of wheels incorporating the '190 technology more difficultdue to the off-axis tension. Specifically, even though the spokes of the'190 patent are orders of magnitude stronger than their metalliccounterparts, the strength of the '190 spokes is slightly decreased fromits maximum strength due to the bend in the spokes as they leave thewheel rim when installed in a wheel.

U.S. Pat. No. 6,036,281 which issued on Mar. 14, 2000, to RichardCampbell and entitled “Low Rotational Mass Bicycle Wheel System”(hereinafter the '281 patent), disclosed a bicycle wheel system havingspokes extending radially from hub to spoke. The spokes are providedwith fittings at its rim end which are constructed with minimal mass andfittings at the hub end which allow adjustment of the tension of thespoke. The spokes are constructed of a bundle of liquid crystal fibershaving no significant creep surrounded by an extruded plastic jacket.

While the spoke presented in the '281 patent certainly represents amilestone in bicycle wheel technology and light-weight wheelmanufacturing, it nevertheless has its challenges with implementation.First of all, there are manufacturing challenges in keeping the spokesaligned with their connectors. In narrow-width wheel applications, thedevice disclosed in the '281 are difficult to install as the alignmentis important. This alignment results in increased assembly costs andoverall product costs.

The present invention resolves these problems by providing spokes thatare both lighter in weight than steel and significantly stronger thansteel, and that are flexible such that they can bend without sufferingdamage. Moreover, due to their significant strength and durability,fewer numbers of spokes are required on wheels while still providing alightweight wheel with superior strength.

SUMMARY OF THE INVENTION

The wheel with high strength flexible spokes of the present inventionprovides the aforementioned advantages by providing a wheel including arim, a hub, and spokes between the rim and hub made of fibrous materialthat causes the spokes to be both lighter in weight and stronger thancomparable steel spokes. The spokes are also flexible and resilient suchthat they can bend while retaining their integrity and strength.

Alternative embodiments of the wheel with high strength flexible spokesof the present invention include nipples for use within the wheel rimsthat provide flexibility in the angle which the spoke extends from therim towards the wheel hub. A shortened nipple which sits fully withinthe rim such that the collar rests firmly against the inside of the rimand is accessible through the access hole formed in the rim is securedusing a blade key received within a keyway for installation. Analternative embodiment includes a nipple formed to have a shoulder thatis rounded and can pivot slightly within the rim to accommodate a slightdeparture angle for the spoke, and is held in place using a keycorresponding to a keyway. The rounded nipple is sized to be receivedfully within the rim of a wheel and is formed with a rounded surface tomate closely with the internal surface of a wheel rim, such that therounded nipple can be secured in place with the spoke extending from thewheel at an angle, while maintaining the straightness of the spoke.

In another alternative embodiment, the rim is formed with spoke holesconfigured to retain the nipples while allowing the nipples to rotatewithin the spoke holes. The hubs are formed with anchor holes which arealso configured to retain anchors while allowing the anchors to rotatewithin the anchor holes. The spokes, having a first end with an attachedtube and a second end having attached anchor, is inserted with the firstend first through anchor hole and subsequently slid through the anchorhole until the tube contacts a corresponding nipple. The tube isthreadably received by the nipple and threaded into the nipple, therebyseating the anchor into anchor hole and pulling the high strengthflexible spoke taut. The configuration of the anchor hole with itscorresponding spoke hole allows the high strength flexible spoke toextend in a straight line from the anchor hole to the spoke hole,preventing the formation of any bends within the spoke resulting in aneven distribution of forces along the high strength flexible spoke.

BRIEF DESCRIPTION OF DRAWINGS

The aforementioned and other advantages of the wheel with flexiblespokes of the present invention will become more apparent to thoseskilled in the art upon making a thorough review and study of thefollowing detailed description of the invention when reviewed inconjunction with the drawings in which like references numerals refer tolike parts, and wherein:

FIG. 1 is a side view of a first preferred embodiment of the wheel withflexible spokes of the present invention, showing the rim, hub, spokesbetween rim and hub, tubes attaching each spoke to the rim, and anchorsattaching each spoke to the hub;

FIG. 2 is a rear detail view of the first preferred embodiment of thewheel with flexible spokes of the present invention, showing the hub,the angle between spokes on the left side of the wheel and spokes on theright side of the wheel, and the angle of the hub surface at the pointof attachment of each spoke to the hub;

FIG. 3 is a cross-sectional view of the first preferred embodiment ofthe wheel with flexible spokes of the present invention, taken acrossline 3-3 of FIG. 1, showing cross-sectional portions of the rim and hub,and showing how each tube attaches each spoke to the rim via a nipple inthe rim, and how each anchor attaches each spoke to the hub;

FIG. 4 is a cross-sectional view of the first preferred embodiment ofthe wheel with flexible spokes of the present invention, taken acrossline 4-4 of FIG. 1, showing a cross-sectional view of the fibers andjacket of one of the spokes;

FIG. 5 is a cross-sectional view of the first preferred embodiment ofthe wheel with flexible spokes of the present invention showingcross-sectional portions of the rim and hub, and showing how each tube,once attached to the rim, would extend away at an angle from the nipplein the rim;

FIG. 6 is a cross-sectional view of an alternative embodiment of thewheel with high strength flexible spokes of the present inventionshowing cross-sectional portions of the rim and hub, and showing ashortened nipple sized to be fully received within the rim and formedwith a keyway to receive a key when secured during assembly of thewheel, and with the spoke extending away at an angle from the nipple inthe rim;

FIG. 7 is a cross-sectional view of an alternative embodiment of thewheel with high strength flexible spokes of the present inventionshowing portions of the rim and hub, and showing a shouldered nipplesized to be fully received within the rim and formed with a keyway toreceive a key when secured during assembly of the wheel, and with theshouldered nipple pivoting slightly within the rim to adjust for slightangular adjustments within the rim, and the spoke extending away at anangle from the nipple in the rim;

FIG. 8 is a cross-sectional view of an alternative embodiment of wheelwith high strength flexible spokes of the present invention showingcross-sectional portions of the rim and hub, and showing a sphericalnipple sized to be fully received within the rim and formed with akeyway to receive a key when secured during assembly of the wheel;

FIG. 9 is a cross-sectional view of the alternative embodiment of wheelwith high strength flexible spokes of the present invention showingcross-sectional portions of the rim and hub, showing the sphericalnipple rotating within the rim to accommodate the angular positioning ofa spoke extending away from the rim with little or no angular changewith the tube head and spoke;

FIG. 10 is an exemplary embodiment of a key for tightening the highstrength flexible spokes of the present invention, and includes a handlehaving a shaft leading to a head formed with a number of keys sized andpositioned to cooperatively engage the keyways on nipples of the presentinvention;

FIG. 11 is a side view of an alternative embodiment of the wheel withflexible spokes of the present invention, showing the rim, hub, spokesbetween rim and hub, tubes attaching each spoke to the rim, and anchorsattaching each spoke to the hub;

FIG. 12 is a front view of an alternative embodiment of the highstrength flexible spoke of the present invention showing the spoke shafthaving a tube attached to a first end and an anchor attached to a secondend;

FIG. 13 is a cross-sectional view of the alternative embodiment of thespoke shaft of the present invention, taken across line 13-13 of FIG.12, showing a cross-sectional view of the fibers and jacket of one ofthe spokes; and

FIG. 14 is a cross-sectional view of the alternative embodiment of thewheel of the present invention, taking across line 14-14 of FIG. 11,showing the hub connected to the rim by several spokes.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a side view of a first preferred embodiment of thewheel with flexible spokes of the present invention is shown andgenerally designated 100. In FIG. 1, the side of wheel 100 facing theviewer can be referred to as the right side of the wheel 100. The sideof wheel 100 opposite the right side can be referred to as the left sideof the wheel 100. The wheel 100 has a wheel axis 104, and a rim 110which has an inner perimeter 112 and an outer perimeter 114.

Still referring to FIG. 1, with reference to FIGS. 2-4, distributedsymmetrically along inner perimeter 112 are spoke holes 120. Each spokehole 120 has a spoke hole width 122. Along the outer perimeter 114 arenipple access holes 124 (not visible in FIG. 1), one nipple access hole124 adjacent each spoke hole 120. Wheel 100 further includes a hub 130having a right flange 132 and a left flange 134 (not visible, behindright flange 132). Each flange 132 and 134 has an inner surface 136 andan outer surface 138. In each flange 132 and 134 are flange holes 140,each flange hole 140 corresponding to a unique spoke hole 120. Eachflange hole 140 has an inner opening 142 in the corresponding innersurface 136, and an outer opening 144 in the corresponding outer surface138. Hub 130 also has a barrel 148 which receives an axle of a bicycle.

Wheel 100 further includes non-rigid spoke members, or spokes 150. Eachspoke 150 has non-rigid fibers 152 covered by a jacket 154 having aninner diameter 156 and an outer diameter 158 which is also the width 158of spoke 150. Each spoke 150 has a length 160. Fibers 152 aresubstantially continuous along the length 160 of spoke 150.Alternatively, one or more of fibers 152 may be shorter than length 160of spoke 150.

Each spoke 150 has an inner end 162 adjacent hub 130, and an outer end164 adjacent rim 110. Each spoke 150 has a tube 170 about its outer end164, and each tube 170 is formed with a tapered bore 171 opening awayfrom the midpoint of the spoke. Each tube 170 is affixed to itscorresponding outer end 164 by inserting the fibers 152 into the tube170, and filling the tube 170 with epoxy 175. Once hardened, the epoxy175 and fibers 152 form a wedge within the tapered bore 171 such thatany tension on the spoke draws the hardened wedge against the taperedbore 171 thereby securing the fiber 152 within the tube 170.Alternatively, tube 170 may be affixed to outer end 164 by any othermaterial of similar strength.

Tube 170 may be equipped with a hexagonal, reinforced head 165 whichprovides for added strength at the hub-end of the tube 170. This ishelpful in preventing breakage for a non-axial tension on spoke 150, andfacilitates the tightening of spoke 150.

Each tube 170 has a tube axis 172 and external spoke threads 174. Eachspoke 150 also has an anchor (or eyelet or ferrule) 180 about its innerend 162. Each anchor 180 is formed with a tapered bore 181 opening awayfrom the midpoint of the spoke. Each anchor 180 is affixed to itscorresponding inner end 162 by inserting the fibers 152 into the anchor180, and filling the tapered bore 181 with epoxy 163. Once hardened, theepoxy 163 and fibers 152 form a wedge within the tapered bore 181 formedin the anchor 180 such that any tension on the spoke 150 draws thehardened wedge against the tapered bore 181 thereby securing the fiber152 within the anchor 180. Alternatively, anchor 180 may be affixed toinner end 162 by any other material of similar strength.

Each flange hole 140 is wider than spoke 150 but narrower than anchor180, such that tube 170 about outer end 164 can be passed through inneropening 142 and outer opening 144, such that the rest of spoke 150 canthen be passed through flange hole 140 until anchor 180 comes intocontact with inner surface 136 around inner opening 142, which causesinner end 162 to be retained in flange hole 140 by anchor 180.

Wheel 100 also includes nipples 190. One nipple 190 is shown in FIG. 1in broken line, inside rim 110. There is a nipple 190 between each spokehole 120 and its corresponding nipple access hole 124. Each nipple 190has a nipple opening 192, nipple threads 194 inside nipple opening 192,a collar 196, and a nipple head 198. Once each spoke 150 is passedthrough flange hole 140 until anchor 180 comes into contact with innersurface 136 around inner opening 142, tube 170 is positioned andthreaded into the corresponding nipple 190 via inter-engagement of spokethreads 174 with nipple threads 194. This causes tube 170 to be retainedin nipple 190 such that tube axis 172 is perpendicular to wheel axis 104(shown in FIG. 1). The retention of tube 170 in nipple 190 and of innerend 162 in flange hole 140 by anchor 180, causes spoke 150 to be heldtaut between rim 110 and hub 130.

FIG. 1 shows eight (8) spokes 150 attached to right flange 132, andeight (8) spokes 150 attached to left flange 134 (not visible, behindright flange 132), for a total of sixteen (16) spokes 150. Wheel 100 mayalternatively have more or fewer than sixteen (16) spokes 150. Forexample, wheel 100 may have twelve (12) spokes 150, six (6) spokes 150attached to each of flanges 132 and 134. While it is also possible tohave different numbers of spokes 150 attached to each of flanges 132 and134, having the same number of spokes attached to each of flanges 132and 134 balances the load on the flanges 132 and 134.

FIG. 2 is a rear view of hub 130. FIG. 2 shows the angle that one of thespokes 150 is attached to right flange 132, and the angle that one ofthe spokes 150 is attached to left flange 134. In FIG. 2, the right sideof wheel 100 is on the right side of FIG. 2, and the left side of wheel100 is on the left side of FIG. 2. Broken line 230 in FIG. 2 representsa plane 230 that bisects wheel 100 between the right side and left sideof wheel 100. Plane 230 is perpendicular to wheel axis 104. Each outersurface 138 has the shape of a conical section that has an angle 240 towheel axis 104. Each spoke 150 extends perpendicularly from thecorresponding outer surface 138. Therefore, each spoke 150 extends fromouter surface 138 at an angle 250 to plane 230. This means that themagnitude of angle 260 between spoke 150 attached to right flange 132and spoke 150 attached to left flange 134, is twice the magnitude ofangle 250.

FIG. 3 shows a partial cross-sectional detail view of a spoke 150 withits inner end 162 retained in flange hole 140 by anchor 180, and tube170 about to be received in nipple 190 in rim 110. FIG. 3 shows hownipple 190 is retained in spoke hole 120. Spoke hole width 122 allowsthe portion of nipple 190 around nipple opening 192 to pass throughspoke hole 120, but does not allow collar 196 to pass through spoke hole120, such that nipple is retained in spoke hole 120 by the tension ofspoke 150 on nipple 190 once tube 170 is threaded into nipple 190. FIG.3 also shows spoke threads 174 which inter-engage with nipple threads194 to thread tube 170 into nipple 190. With tube 170 retained in nipple190, tube axis 172 is perpendicular to wheel axis 104 (not shown) andintersects the corresponding spoke hole 120. Spoke holes 120 lie inplane 230. While spoke holes 120 may alternatively be adjacent plane230, spoke holes 120 being in plane 230 causes the forces of spokes 150to be placed on rim 110 where plane 230 intersects rim 110, which is themiddle of the inner perimeter 112 of rim 110. With spoke holes 120 inplane 230, and each tube 170 received in the corresponding nipple 190,tube axis 172 also lies in plane 230.

In FIG. 3, tube axis 172 coincides with the broken line representingplane 230. However, because each spoke 150 extends at angle 250 to plane230, each spoke 150 extends from its tube 170 at angle 250 to tube axis172. This means that there is a bend in spoke 150 at an angle 250 at thepoint 320 where spoke 150 protrudes from tube 170. With steel spokes,such a bend would weaken the spoke and ultimately cause the spoke tofail. However, with spokes 150, such a bend does not damage spokes 150,because fibers 152 are flexible and resilient yet strong such thatspokes 150 retain their integrity and strength even when bent undertension in the manner described. Therefore, spokes 150 can bend withoutweakening or failing. Furthermore, each of spokes 150 is three times asstrong, and weighs half as much, as a steel spoke that would otherwisebe used in its place. This allows the width 158 of each of spokes 150 tobe greater than that of a steel spoke that would be used in its place.In the alternative, the width 158 of each spoke 150 may be less than orequal to the width of a steel spoke that would be used in its place; thestrength of each of spokes 150 may be greater or less than three timesthat of a steel spoke that would be used in its place; and the weight ofeach of spokes 150 may be greater or less than half that of a steelspoke that would be used in its place.

Rim 110, hub 130, tube 170, anchor 180 and nipple 190, in a preferredembodiment, are made of aluminum. Alternatively, any of rim 110, hub130, tube 170, anchor 180 or nipple 190 may be made of any othermaterial of comparable strength. In a preferred embodiment of thepresent invention, fibers 152 are a bundle of thermotropic liquidcrystal fibers that exhibit high strength, low creep, and weatherresistance. For instance, such fibers could be PBO Zylon® fiber, astrong yet lightweight fiber, available from Toyobo®. Alternatively,fibers 152 may be made of any other material having comparable weightand strength. Jacket 154 is made of Rilsan®. Alternatively, jacket 154may be made of any other material having comparable weight and strength.Each nipple access hole 124 allows access to nipple head 198 so that itcan be turned to facilitate the threading of nipple 190 onto tube 170.For instance, a hexagonal head nut-driver may be positioned over nipple190 and rotated to tighten spoke 150 in place.

FIG. 4 shows a cross-sectional detail view of the inside of a spoke 150,showing the fibers 152, and inner diameter 156 of jacket 154. Fibers 152are gathered in forty-four (44) bundles 410 made of nine-hundred andninety-six (996) filaments each, for a total of 43,824 filaments insingle spoke 150. The large number of filaments is one factorcontributing to the increased strength of spoke 150, while minimizingthe weight of spoke 150. Spoke 150 has a breaking strength of 3,600pounds. Alternatively, the number of bundles 410 may be greater or lessthan forty-four (44). Additionally, the the weight of each of spokes 150may be greater or less than half that of a steel spoke that would beused in its place.

Rim 110, hub 130, tube 170, anchor 180 and nipple 190, in a preferredembodiment, are made of aluminum. Alternatively, any of rim 110, hub130, tube 170, anchor 180 or nipple 190 may be made of any othermaterial of comparable strength. In a preferred embodiment of thepresent invention, fibers 152 are a bundle of thermotropic liquidcrystal fibers that exhibit high strength, low creep, and weatherresistance. For instance, such fibers could be PBO Zylon® fiber, astrong yet lightweight fiber, available from Toyobo®. Alternatively,fibers 152 may be made of any other material having comparable weightand strength. Jacket 154 is made of Rilsan®. Alternatively, jacket 154may be made of any other material having comparable weight and strength.Each nipple access hole 124 allows access to nipple head 198 so that itcan be turned to facilitate the threading of nipple 190 onto tube 170.For instance, a hexagonal head nut-driver may be positioned over nipple190 and rotated to tighten spoke 150 in place.

FIG. 4 shows a cross-sectional detail view of the inside of a spoke 150,showing the fibers 152, and inner diameter 156 of jacket 154. Fibers 152are gathered in forty-four (44) bundles 410 made of nine-hundred andninety-six (996) filaments each, for a total of 43,824 filaments insingle spoke 150. The large number of filaments is one factorcontributing to the increased strength of spoke 150, while minimizingthe weight of spoke 150. Spoke 150 has a breaking strength of 3,600pounds. Alternatively, the number of bundles 410 may be greater or lessthan forty-four (44). Additionally, the number of filaments in eachbundle 410 may be greater or less than 996. As a result, the breakingstrength of spoke 150 may be greater or less than 3,600 pounds.

Referring to FIG. 5, a cross-sectional view of the first preferredembodiment of the wheel with flexible spokes of the present inventionshowing cross-sectional portions of the rim and hub is shown. As can beappreciated from FIG. 5, the width of rim 110 is just slightly widerthan the width of nipple 190. As a result, it is necessary that thenipple be aligned so that the tube extends radially inward from rim 110.Because of this positioning, it is important that spoke 150 be flexibleas it leaves tube 190 so as to accommodate angle 250 without anydecrease in strength and durability. Due to the number of fiber strandscontained within spoke 150, there is no noticeable decrease in strengthdespite the off-axis tension.

When tension is applied to spoke 150, collar 196 strikes the insidesurface of rim 110 and maintains the nipple 190, and correspondingsleeve, in its perpendicular arrangement.

Referring now to FIGS. 6 through 9, a number of alternative embodimentsof the wheel with high strength flexible spokes of the present inventionare shown and include variations on the nipple and rim.

Referring initially to FIG. 6, the wheel with high strength flexiblespokes of the present invention is shown and includes a shortened nipplegenerally designated 450. Shortened nipple 450 is sized to be fullyreceived within the rim 110. Nipple 450 includes a nipple head 452 and acollar 460 sized to rest against the interior of the rim 110 and allownipple opening 456 to pass through spoke hole 120. Shortened nipple 450is formed with a threaded bore 454 passing longitudinally along axis 172from nipple opening 456. Threaded bore 454 is sized to threadablyreceive head tube 170.

Shortened nipple 450 is formed with a keyway 462 to receive a key whensecured during assembly of the wheel. More specifically, nipple head 452is formed with a pattern of keyways 462 to receive a correspondinglyshaped key to maintain the rotational position of nipple 450 along axis172 during the installation of spoke 150. By inserting a key intokeyways 462, the nipple 450 may be held in place while head tube isrotated such that head tube threads 174 enter nipple 450.

As shown in FIG. 6, spoke 150 may extend away from axis 172 by an angle250 as described in conjunction with alternative embodiments.

Referring now to FIG. 7, a cross-sectional view of an alternativeembodiment of the wheel with high strength flexible spokes of thepresent invention is equipped with a shouldered nipple generallydesignated 480. Shouldered nipple 480 includes an insert 482 having adiameter 484 which is slightly less than the diameter of spoke hole 120of rim 110. Shoulder 485 is larger in diameter than insert diameter 484such that the shoulder 485 rests on the inside surface of rim 110.

Shouldered nipple 480 is formed with a threaded bore 488 which passesfrom nipple opening 483 through to nipple head 486, and includes threads492 matching threads 174. Threaded bore 488 is sized to threadablyreceive threads 174 on tube head 170 during the assembly of the wheelwith high strength flexible spokes of the present invention.

From FIG. 7 it can been seen that shoulder 485 is rounded andcorresponds with a mating surface 494 on rim 110 such that the axis 172of nipple 480 may vary slightly within rim 110. Specifically, the matingsurface 494 allows the shouldered nipple 480 to pivot slightly withinthe rim 110 to accommodate slight angular adjustments within the rim,such that the spoke 150 can extend away at an angle 250 from the nipple480 and rim 110.

A number of keyways 490 are formed in nipple head 486 such that acorresponding key (not shown) can be inserted into keyways 490 tomaintain the rotational position of nipple 480 during the threading oftube head 170 into threaded bore 488, and when tightening the spoke 150using hexagonal head 165. Also, nipple 480 is sized to be fully receivedwithin access hole 124 in rim 100.

Referring now to FIGS. 8 and 9, cross-sectional views of an alternativeembodiment of wheel with high strength flexible spokes of the presentinvention showing cross-sectional portions of the rim and hub, andshowing a spherical, or rounded, nipple generally designated 500.Rounded nipple 500 is formed with a spherical or near spherical body 502having a bore 506 along axis 172 and formed with threads 504 from inlet506 through end 510.

Rim 110 is formed with nipple seat 508 that is shaped to receive roundednipple 500 to retain nipple 500 in position along axis 172 of rim 100.FIG. 9 depicts the insertion of a spoke 150 into rounded nipple 500 bythreadably rotating spoke 150 along axis 518 and advancing the spoke 150in direction 514.

Rounded nipple 500 is formed with a number of keyways 512 sized toreceive a key, such as the key 550 shown in FIG. 10, having a handle 552and a shaft 554 leading to a head 556 formed with keys 558 positionedand sized to correspond to keyways 512 on rounded nipple 500. It is tobe appreciated that the number, size, positioning of the keys 558 mayvary to accommodate keyway size, shapes, and patterns of nipplesdescribed herein.

Head 556 of key 550 is formed to have a diameter 560 that is less thanthe diameter of access hole 124. Accordingly, key 550 can be insertedinto rim 110 during the wheel assembly process to engage keys 558 intokeyways 512 to maintain the rotational position of rounded nipple 500 ashead tube 170 is threaded into nipple 500.

Also from FIG. 9, the rotation of rounded nipple 500 within rim 110 isshown. Rounded nipple 500 rotates within the rim 110 to accommodate theangular positioning of a spoke 150 extending away from the rim 110 withlittle or no angular change with the tube head and spoke. Specifically,rounded nipple 500 rests against nipple seats 508 and can rotate about acenter of rotation 522 such that the axis 518 of tube head 174 can movewithin range 520. This range 520 allows the spoke 150 to maintain arelatively straight line between tube head 174 and anchor 180 of hub130. This straightness along axis 518 provides additional strength asall fibers 152 within spoke 150 are stressed similarly along thelongitudinal axis of the spoke.

Referring now to FIG. 10, an exemplary embodiment of a key tool fortightening the high strength flexible spokes of the present invention isshown and generally designated 550. Key tool 550 includes a handle 552having a shaft 554 leading to a head 556 formed with a number of keys558 sized and positioned to cooperatively engage the keyways on nipplesof the present invention. The diameter 560 of head 556 is intended to besized to be insertable through the access hole 124 in the rim 110 asdisclosed herein to engage the nipples described to facilitate the highstrength flexible spokes of the present invention. It is to beappreciated that the key tool 550 is shown in FIG. 10 to have four keys558 which, in a preferred embodiment, correspond to the inserts shown tohave four keyways. It is to be appreciated further, that the number,size and positioning of keys 558 can vary to accommodate a nipple formedwith different configurations of keyways.

Referring now to FIG. 11, a side view of an alternative embodiment ofthe wheel with high strength flexible spokes of the present invention isshown and generally designated 600. In the alternative embodiment of thepresent invention, the wheel 600 is constructed to be used in heavy dutyand extremely demanding applications requiring greater strength,stability, and rigidity, such as for use in motorcycles. The wheel 600includes a hub 604, a plurality of spokes 606, a rim 608, and a tire602.

In the alternative embodiment, the hub 604 and rim 608 are constructedof aluminum. Alternatively, hub 604 and rim 608 may be made of any othermaterial of comparable strength. The hub 604 and rim 608 are constructedhaving thicker walls and larger surface areas as compared to thealternative embodiments aforementioned. The increase in size of the hub604 and rim 608 increases the structural strength and durability of eachpart. The hub 604 has a disc brake mounting surface 614 which allows theattachment of a disc brake assembly.

Each spoke 606 includes a spoke shaft 618 having an anchor 612 attachedto one end and a tube 630 attached to the opposite end. The spoke shaft618 is substantially similar in construction to the flexible, non-rigidspokes of previous embodiments aforementioned. The spoke shaft 618includes fibers 660 (shown in FIG. 13) disposed within a jacket 664. Thenumber of fibers 660 used to construct spoke shaft 618 is increased tocorrespond with the increased strength requirements of the wheel 600.The increased number of fibers 660 thereby increases the internaldiameter 662 (shown in FIG. 13) and external diameter 666 (shown in FIG.13) of jacket 664. The tube 630 is formed with a first section having ahexagonal exterior 632 and a second section having a threaded exterior634. The anchor 612 is formed with a body 626 (shown in FIG. 12) havinga retaining shaft 624 (shown in FIG. 12) extending therefrom. The tube630 and anchor 612 are constructed of aluminum or any other material ofcomparable strength.

The anchor 612 of each spoke 606 is retained by hub 604 and the threadedexterior 634 of tube 630 on the opposite end of the spoke 606 isthreaded into a threaded bore 635 (shown in FIG. 12) of a correspondingnipple 610 retained within rim 608 of wheel 600, whereby the spoke shaft618 projects and extends from the rim 608 to the hub 604 in a straightline. By extending from the nipple 610 and the tube 630 in a straightline it prevents bends from forming in the spoke shaft 618 at the pointwhere the spoke shaft 618 protrudes from the nipple 610 and the tube630, thereby equally spreading the force along each fiber 660 of thespoke shaft 618 and preventing concentrated forces. Each spoke 606connects the hub 604 to the rim 608 at specific locations to maintainthe hub 604 in the center of the rim 608 to form wheel 600.

The tire 602 is affixed onto the rim 608, thereby completing theassembly of wheel 600 which has greater strength, durability, andrigidity when compared to a similarly sized wheel made of steelcomponents. Further, the wheel 600 is substantially lighter than asimilarly sized steel wheel.

Referring now to FIG. 12, a side view of an alternative embodiment ofspoke 606 of the present invention is shown. The spoke 606 includes aspoke shaft 618 with an attached anchor 612 located at one end and atube 630 located at the opposite end. As shown, spoke 606 has a centralaxis 633 in which the centers of the anchor 612, spoke shaft 618, tube630, and nipple 610 are aligned.

The anchor 612 is formed with a body 626 having curved shoulder 625which transitions the body 626 into a retaining shaft 624 extendingtherefrom, where the body 626 has an eternal diameter larger than theexternal diameter of retaining shaft 624. The anchor 612 is furtherformed with a tapered bore 627 (shown in dashed lines), tapering fromthe body 626 towards the retaining shaft 624.

The tube 630 is formed with a first section having a hexagonal exterior632 and a second section having a threaded exterior 634. The tube 630 isfurther formed with a tapered bore 631 (shown in dashed lines) taperingfrom the first section of the tube 630 having the hexagonal exterior 632to the end of tube 630 having the threaded exterior 634.

Nipple 610 is formed with a body 637 having a hexagonal exterior 636 atone end and a spherical flange 638 attached at the opposite end. Thenipple 610 is further formed with a threaded bore 635. The threads ofthe threaded bore 635 corresponds with the threads of threaded exterior634 of tube 630, allowing tube 630 to be inserted and subsequentlythreaded into nipple 610, as shown. It is contemplated that tube 630 andnipple 610 may have alternative exterior shapes such as a square toallow the use of tools to grip onto the exterior of the tube 630 and thenipple 610 to aid in threading the tube 630 into the nipple 610.

Each anchor 612 is affixed to its corresponding end of spoke shaft 618by inserting the fibers 660 (not shown) into the tapered bore 627 ofanchor 612, and filling the tapered bore 627 with epoxy. Once hardened,the epoxy and fibers 660 form a wedge within the tapered bore 627 suchthat any tension on the spoke shaft 618 draws the hardened wedge againstthe tapered bore 627, thereby securing the spoke shaft 618 within theanchor 612. The use of epoxy is not meant to be limiting and it iscontemplated that any other material of similar strength may be used.The spoke shaft 618 is affixed to tube 630 utilizing the same method.Alternatively, the spoke shaft 618 may be affixed to the anchor 612 andtube 630 using mechanical means such as utilizing a tapered crimp sleeveattached to fibers 660. Once attached, the tapered crimp sleeve forms awedge such that any tension on the spoke shaft 618 draws the taperedcrimp sleeve against the tapered bore 627 or 631, thereby securing thespoke shaft 618 within the anchor 612 and tube 630.

Referring now to FIG. 13, a cross-sectional view of a spoke shaft 618taken at line 13-13 of FIG. 12 is shown. The spoke shaft 618 includesfibers 660 disposed within jacket 664 having internal diameter 662 andexternal diameter 666. The spoke shaft 618 is substantially similar inconstruction to the spokes of previous embodiments aforementioned. Inthe preferred embodiment as described above in FIG. 1, the fibers 152 ofspoke 150 are gathered in forty-four (44) bundles, with each bundle madeof nine-hundred ninety-six (996) filaments, for a total of 43,824filaments in a single spoke shaft 618. The spoke 606 of the alternativeembodiment of the present invention requires an increased level ofstrength as compared to spoke 150 of wheel 100, therefore the number offibers 660 used to construct spoke shaft 618 is increased to meet thestrength requirements of wheel 600. The increase in the number of fibers660 thereby increases the internal diameter 662 and external diameter666 of the jacket 664.

The fibers 660 are a bundle of thermotropic liquid crystal fibers thatexhibit high strength, low creep, and weather resistance. For instance,such fibers could be PBO Zylon® fiber, a strong yet lightweight fiber,available from Toyobo®. Alternatively, fibers 660 may be made of anyother material having comparable weight and strength characteristics.Jacket 664 is made of Rilsan®. Alternatively, jacket 664 may be made ofany other material having comparable strength, weight, and durabilitycharacteristics. As a result of the materials used and constructionmethod, the spoke 606 of the present invention is high-strength,non-rigid, flexible, and lightweight. Further, the spoke 606 has atleast three times the strength while weighing approximately half that ofa similar sized steel spoke.

Referring now to FIG. 14, a cross-sectional view of the wheel 600 takenat line 14-14 of FIG. 11 is shown. In FIG. 14, the right side of wheel600 is on the right side of FIG. 14, and the left side of wheel 600 ison the left side of FIG. 14. A plane 650, represented by a broken line,bisects wheel 600 between the right side and left side of wheel 600.Plane 650 is perpendicular to a wheel axis 651, where the wheel axis 651extends through an axle housing 652 of hub 604. Wheel axis 651 definesthe center of the wheel 600. Plane 650 partitions rim 608 into aleft-half 619 and a right-half 616, and partitions hub 604 into aleft-half having a left flange 613 and a right-half having a rightflange 615. As shown, the wheel 600 has a disc brake mounting surface614 however, it is contemplated that the wheel 600 may be constructedwithout a disc brake mounting surface 614. It is also contemplated thatthe wheel 600 may be manufactured to be both a front free wheel and arear driving wheel.

Distributed symmetrically along the perimeter of the rim 608 is aplurality of spoke holes 609. The spoke holes 609 are distributed evenlybetween the left-half 619 and right-half 616 of rim 608 in analternating pattern, such as a first spoke hole located on theleft-half, a second spoke hole located on the right half, a third spokehole located on the left-half and so forth. This ensures an even numberof spoke holes 609 is located on each half of the rim 608 to balance theload on the rim 608.

The hub 604 is formed with a plurality of anchor holes 617 around theperimeter of the left flange 613 and right flange 615. The anchor holes617 are distributed evenly between the left flange 613 and right flange615. As shown, the right flange 615 has an inner surface 642 and anouter surface 640 and the left flange 613 has an inner surface 646 andan outer surface 644. With reference to FIG. 1, the right flange 615have anchor holes 617 formed in a staggered pattern where eachsubsequent anchor hole 617 alternates between the inner surface 642 andouter surface 640 of the right flange 615. The anchor holes 617 formedin left flange 613 are configured in substantially the same manner as inthe right flange 615.

Each spoke hole 609 corresponds to an anchor hole 617, where a straightline projected from the center of the spoke hole 609 intersects thecenter of the anchor hole 617. Furthermore, the spoke holes 609 areformed in rim 608 at an angle 654 and anchor holes 617 are formed withan angle 656, where angle 654 and 656 are equal. This allows the spokeshaft 618 to extend from the anchor 612 and tube 630 in a straight linethereby avoiding any bends on spoke shaft 618. This allows the evendistribution of forces along the fibers of the spoke shaft 618 andprevents any concentrated forces on the spoke shaft 618. Depending onthe type of lacing used and the total number of spokes 606, the angle654 of spoke holes 609, and angle 656 of the anchor holes 617 may vary.For example, a three-cross wheel will have different spoke angles whencompared to a four-cross wheel.

Spoke hole 609 is formed to correspond with the shape and size of thenipple 610 to allow nipple 610 to seat and be retained within spoke hole609 and includes a nipple seat to retain the spherical flange 638 ofnipple 610. The spherical flange 638 of the nipple 610 is capable ofangular rotation within the nipple seat. Anchor hole 617 is formed tocorrespond with the shape and size of the anchor 612 to allow anchor 612to seat and retained within anchor hole 617. Anchor hole 617 includes ashoulder mating surface for rounded shoulder 625, where rounded shoulder625 is capable of angular rotation when pressed against the shouldermating surface.

The anchor holes 617 is formed with a wider diameter than spoke 606 andtube 630 but narrower than the body 626 of anchor 612, such that tube630 affixed to the spoke shaft 618 can be passed through anchor hole617, allowing the remainder of the spoke shaft 618 to pass throughanchor hole 617 until anchor 612 comes into contact with the anchor hole617 and tube 630 comes into contact with nipple 610. The tube 630 isthreaded into the corresponding nipple 610 via inter-engagement ofexternal threads 634 with threaded bore 635. The tube 630 is threadedinto nipple 610 by holding the hexagonal exterior 636 of nipple 610stationary with a wrench and rotating the spoke 606 by rotating the tube630 by the hexagonal exterior 632 with an alternative wrench. Therounded shoulder 625 and spherical flange 638 provides a smooth,low-friction surface which allows the spoke 606 to rotate as the spoke606 is being tensioned. The tension retains tube 630 and nipple 610 inspoke whole 609 and anchor 612 in anchor hole 617, causing spoke shaft618 to be held taut in a substantially straight line between rim 608 andhub 604, maintaining center alignment of the hub 604 relative to the rim608. The straightness of spoke 606 provides additional strength as allfibers 660 within spoke 606 are tensioned equally along the longitudinalaxis of the spoke 606.

In wheel 600 of the alternative embodiment of the present invention, thewheel has 36 spokes (as shown in FIG. 11). A total of 18 spokes areattached between the right flange 615 and right-half 616 of rim 608, and18 spokes are attached between left flange 613 and left-half 619 of rim608. Wheel 600 may alternatively have more or fewer than 36 spokes 606.For example, wheel 600 may have 32 spokes. While it is possible to havedifferent numbers of spokes attached to the hub 604, having the samenumber of spokes attached to each of the flanges 613 and 615 balancesthe load on the hub 604.

While the wheel with high strength flexible spokes of the presentinvention as herein shown and disclosed in detail is fully capable ofobtaining the objects and providing the advantages herein before stated,it is to be understood that it is merely illustrative of preferred andalternative embodiments of the invention and that no limitations areintended to the details of construction or design herein shown otherthan as described in the appended claims.

I claim:
 1. A method of manufacturing a lightweight wheel, comprising:providing a rim having a plurality of spoke holes formed at a spoke holeangle, wherein said plurality of spokes holes are evenly distributedbetween a left side and a right side of said rim; providing a hubcomprising a left flange having an inner surface and an outer surface ona left side of said hub and a right flange having an inner surface andan outer surface on a right side of said hub; providing a plurality ofhigh strength flexible spokes having a central axis, each of said highstrength flexible spokes comprising a flexible spoke shaft havingnon-rigid fibers encased in a non-rigid jacket having a first end wedgeand a second end wedge, an anchor having a tapered bore receiving saidfirst end wedge, and a tube having a tapered bore receiving said secondend wedge, wherein said first end wedge and said second end wedgeconsist of said non-rigid fibers and an epoxy; providing a nipple housedwithin said spoke hole of said rim; and attaching each of said pluralityof high strength flexible spokes between said hub and said rim in astraight line, wherein said anchor is affixed to said anchor hole andsaid tube is affixed to said nipple, thereby mechanically fastening saidhub to said rim.